POLYCARBONATE COMPOSITION

• US 20150079375A1
• Filed: 05/16/2012
• Published: 03/19/2015
• Est. Priority Date: 05/16/2012
• Status: Active Grant

• Current Assignee: SHPP Global Technologies BV
• Original Assignee: Sabic Innovative Plastics IP BV (Government of Saudi Arabia)
• Inventors: Yang, Jian, Van Zyl, Andries J. P., Van de Grampel, Robert Dirk, 4. Choi, Jong-Min
• Granted Patent: US 9,169,391 B2
• Time in Patent Office: Days
• US Class Current: 428/220
• CPC Class Codes: C08G 77/448 containing polycarbonate sequences
• CPC Class Codes: C08K 2003/2241 Titanium dioxide
• CPC Class Codes: C08K 7/14 Glass
• CPC Class Codes: C08L 2205/02 containing two or more polymers of the same C08L -group
• CPC Class Codes: C08L 2205/025 containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
• CPC Class Codes: C08L 2205/03 containing three or more polymers in a blend
• CPC Class Codes: C08L 2205/035 containing four or more polymers in a blend
• CPC Class Codes: C08L 69/005 Polyester-carbonates
• CPC Class Codes: C08L 83/10 Block- or graft-copolymers containing polysiloxane sequences obtained by polymerising a compound having a carbon-to-carbon double bond on to a polysiloxane C08L51/08, C08L53/00

Abstract

A composition includes at least one poly(aliphatic ester)-polycarbonate copolymer, a polysiloxane-polycarbonate copolymer, and glass fibers. The composition exhibits good flow, aesthetic, and impact properties.

Claims

1. A composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 40,000;

a polysiloxane-polycarbonate copolymer present in an amount less than the weight percentage of the first poly(aliphatic ester)-polycarbonate copolymer; and

glass fibers;

wherein the composition has a flexural modulus measured according to ISO 178 of at least 3000 MPa.

2. The composition of claim 1, wherein an ester repeat unit of the first poly(aliphatic ester)-polycarbonate copolymer is derived from sebacic acid.

3. The composition of claim 1, comprising up to about 75 wt % of the first poly(aliphatic ester)-polycarbonate copolymer.

4. The composition of claim 1, further comprising a second poly(aliphatic ester)-polycarbonate copolymer;

wherein a weight average molecular weight of the second poly(aliphatic ester)-polycarbonate copolymer is greater than the weight average molecular weight of the first poly(aliphatic ester)-polycarbonate copolymer.

5. The composition of claim 4, wherein the composition has a melt volume rate measured according to ASTM D1238 of at least 4 cm³/10 min.

6. The composition of claim 4, wherein a weight ratio of the first poly(aliphatic ester)-polycarbonate copolymer to the second poly(aliphatic ester)-polycarbonate copolymer is at least 2:

1.

7. The composition of claim 4, wherein the second poly(aliphatic ester)-polycarbonate copolymer has a weight average molecular weight of from about 30,000 to about 40,000.

8. The composition of claim 4, comprising from about 15 to about 75 wt % of the first poly(aliphatic ester)-polycarbonate copolymer.

9. The composition of claim 4, comprising from about 5 to about 50 wt % of the second poly(aliphatic ester)-polycarbonate copolymer.

10. The composition of claim 1, comprising from about 5 to about 35 wt % of the glass fibers.

11. The composition of claim 1, wherein the composition exhibits a gloss measured according to ASTM D2457 (at 60°

) of at least 40.

12. The composition of claim 1, wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm³/10 min;

and a notched Izod impact strength measured according to ASTM D256 of at least 150 J/m.

13. The composition of claim 1, wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm³/10 min;

a flexural modulus measured according to ISO 178 of at least 3000 MPa; and

a notched Izod impact strength measured according to ASTM D256 of from about 150 J/m to about 300 J/m.

14. The composition of claim 1, wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm³/10 min;

a flexural modulus measured according to ISO 178 of at least 3000 MPa; and

a notched Izod impact strength measured according to ASTM D256 of at least 200 J/m.

15. The composition of claim 1, wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm³/10 min;

a flexural modulus measured according to ISO 178 of at least 3500 MPa; and

a notched Izod impact strength measured according to ASTM D256 of at least 250 J/m.

16. The composition of claim 1, wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 9 cm³/10 min;

a flexural modulus measured according to ISO 178 of at least 3000 MPa; and

a notched Izod impact strength measured according to ASTM D256 of at least 250 J/m.

17. The composition of claim 1, comprising from about 5 to about 25 wt % of the polysiloxane-polycarbonate copolymer.

18. The composition of claim 1, wherein the aliphatic ester is derived from an aliphatic dicarboxylic acid that has a total of from 8 to 12 carbon atoms.

19. The composition of claim 1, wherein the first poly(aliphatic ester)-polycarbonate copolymer contains from about 2 to about 13 mol % of aliphatic ester units.

20. The composition of claim 19, wherein the first poly(aliphatic ester)-polycarbonate copolymer contains from about 87 to about 98 mol % of carbonate units derived from bisphenol-A.

21. The composition of claim 19, wherein the aliphatic ester units are derived from sebacic acid.

22. The composition of claim 1, wherein a siloxane block chain length of the polysiloxane-polycarbonate copolymer is from about 35 to about 55.

23. The composition of claim 1, wherein a siloxane block chain length of the polysiloxane-polycarbonate copolymer is from about 30 to about 100.

24. The composition of claim 1, wherein the polysiloxane-polycarbonate copolymer has a siloxane block content of from about 15 wt % to about 25 wt %.

25. The composition of claim 1, wherein the polysiloxane-polycarbonate copolymer has a siloxane block content of from greater than zero to about 25 wt %.

26. The composition of claim 1, wherein the composition has a total softblock content of less than 3.5 wt %.

27. The composition of claim 1, wherein the composition comprises from about 0.5 wt % to about 6 wt % of siloxane originating from the polysiloxane-polycarbonate copolymer.

28. The composition of claim 1, wherein the glass fibers are non-bonding glass fibers.

29. An article made from the composition of claim 1, that has a wall with a thickness of at least 0.3 mm and less than 1 mm.

30. The article of claim 29, wherein the article is a part of a cellphone, a MP3 player, a computer, a laptop, a camera, a video recorder, an electronic tablet, a hand receiver, a kitchen appliance, or an electrical housing.

31. A composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 25,000;

a second poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 30,000 to about 40,000;

a polysiloxane-polycarbonate copolymer present in an amount less than the combined weight percentage of the first and second poly(aliphatic ester)-polycarbonate copolymers; and

glass fibers;

wherein the composition has a flexural modulus measured according to ISO 178 of at least 3000 MPa.

32. The composition of claim 31, wherein the first poly(aliphatic ester)-polycarbonate copolymer and the second poly(aliphatic ester)-polycarbonate copolymer both include ester units derived from sebacic acid.

33. The composition of claim 31, comprising from about 55 to about 85 wt % of the first poly(aliphatic ester)-polycarbonate copolymer and the second poly(aliphatic ester)-polycarbonate copolymer.

34. The composition of claim 31, wherein a weight ratio of the first poly(aliphatic ester)-polycarbonate copolymer to the second poly(aliphatic ester)-polycarbonate copolymer is from about 1.5 to about 15.

35. The composition of claim 31, wherein the first poly(aliphatic ester)-polycarbonate copolymer contains from about 4 to about 7 mol % of aliphatic ester units.

36. The composition of claim 35, wherein the first poly(aliphatic ester)-polycarbonate copolymer contains from about 93 to about 96 mol % of carbonate units derived from bisphenol-A.

37. The composition of claim 35, wherein the aliphatic ester units are derived from sebacic acid.

38. The composition of claim 31, wherein the second poly(aliphatic ester)-polycarbonate copolymer contains from about 7 to about 13 mol % of aliphatic ester units.

39. The composition of claim 38, wherein the second poly(aliphatic ester)-polycarbonate copolymer contains from about 87 to about 93 mol % of carbonate units derived from bisphenol-A.

40. The composition of claim 38, wherein the aliphatic ester units are derived from sebacic acid.

41. The composition of claim 31, wherein both the first poly(aliphatic ester)-polycarbonate copolymer and the second poly(aliphatic ester)-polycarbonate copolymer contain aliphatic ester units derived from sebacic acid and carbonate units derived from bisphenol-A.

42. A composition comprising:

from about 35 wt % to about 75 wt % of a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 25,000;

from about 5 wt % to about 30 wt % of a second poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 30,000 to about 40,000;

from about 9 wt % to about 20 wt % of a polysiloxane-polycarbonate copolymer; and

from about 10 wt % to about 20 wt % of non-bonding glass fibers;

wherein the first poly(aliphatic ester)-polycarbonate copolymer and the second poly(aliphatic ester)-polycarbonate copolymer both comprise ester units derived from sebacic acid;

wherein the composition exhibits a gloss measured according to ASTM D2457 (at 60°

) of at least 40.

43. The composition of claim 42, wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 2 cm³/10 min;

a flexural modulus measured according to ISO 178 of at least 3000 MPa; and

a notched Izod impact strength measured according to ASTM D256 of at least 90 J/m.

44. The composition of claim 42, comprising from about 50 to about 65 wt % of the first poly(aliphatic ester)-polycarbonate copolymer.

45. The composition of claim 42, wherein a weight ratio of the first poly(aliphatic ester)-polycarbonate copolymer to the second poly(aliphatic ester)-polycarbonate copolymer is from about 1.5 to about 15.

46. The composition of claim 45, wherein a weight ratio of the first poly(aliphatic ester)-polycarbonate copolymer to the second poly(aliphatic ester)-polycarbonate copolymer is from about 2 to about 4.

47. A composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 40,000;

a polysiloxane-polycarbonate copolymer present in an amount less than the weight percentage of the first poly(aliphatic ester)-polycarbonate copolymer; and

glass fibers;

wherein the composition has a flexural modulus measured according to ISO 178 of at least 3000 MPa; and

wherein the composition exhibits a gloss measured according to ASTM D2457 (at 60°

) of at least 40.

48. The composition of claim 47, wherein the composition contains from about 10 wt % to about 20 wt % of the glass fibers.

49. The composition of claim 47, wherein the composition exhibits a gloss measured according to ASTM D2457 (at 60°

) of at least 60.

50. The composition of claim 47, further comprising a second poly(aliphatic ester)-polycarbonate copolymer;

wherein the first poly(aliphatic ester)-polycarbonate copolymer has a weight average molecular weight of from about 15,000 to about 25,000;

wherein the second poly(aliphatic ester)-polycarbonate copolymer has a weight average molecular weight of from about 30,000 to about 40,000; and

wherein the polysiloxane-polycarbonate copolymer is present in an amount less than the combined weight percentage of the first and second poly(aliphatic ester)-polycarbonate copolymers.

51. The composition of claim 47, wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm³/10 min;

and wherein the composition exhibits a notched Izod impact strength measured according to ASTM D256 of at least 150 J/m.

52. The composition of claim 47, wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm³/10 min;

a flexural modulus measured according to ISO 178 of at least 3500 MPa; and

a notched Izod impact strength measured according to ASTM D256 of at least 250 J/m.

53. The composition of claim 47, wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 9 cm³/10 min;

a flexural modulus measured according to ISO 178 of at least 3000 MPa; and

a notched Izod impact strength measured according to ASTM D256 of at least 250 J/m.

54. The composition of claim 47, wherein the first poly(aliphatic ester)-polycarbonate copolymer contains from about 6 to about 8 mol % of aliphatic ester units.

55. The composition of claim 47, wherein the first poly(aliphatic ester)-polycarbonate copolymer contains from about 2 to about 13 mol % of aliphatic ester units.

56. The composition of claim 55, wherein the first poly(aliphatic ester)-polycarbonate copolymer contains from about 87 to about 98 mol % of carbonate units derived from bisphenol-A.

57. The composition of claim 54, wherein the aliphatic ester units are derived from sebacic acid.

58. An article made from the composition of claim 47.

59. The article of claim 58, wherein the article is a part of a cellphone, a MP3 player, a computer, a laptop, a camera, a video recorder, an electronic tablet, a hand receiver, a kitchen appliance, or an electrical housing.

68. The composition of claim 55, wherein the aliphatic ester units are derived from sebacic acid.

60. A composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 25,000;

a second poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 30,000 to about 40,000;

a polysiloxane-polycarbonate copolymer; and

about 10 wt % of glass fibers;

wherein a weight ratio of the first poly(aliphatic ester)-polycarbonate copolymer to the second poly(aliphatic ester)-polycarbonate copolymer is at least 2;

1; and

wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 9 cm³/10 min;

a flexural modulus measured according to ISO 178 of at least 3000 MPa;

a notched Izod impact strength measured according to ASTM D256 of at least 250 J/m; and

a gloss measured according to ASTM D2457 (at 60°

) of at least 40.

61. The composition of claim 60, containing up to about 65 wt % of the first poly(aliphatic ester)-polycarbonate copolymer.

62. An article made from the composition of claim 60.

69. An article made from the composition of claim 61.

63. An article made from a composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 25,000;

a second poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 30,000 to about 40,000;

a polysiloxane-polycarbonate copolymer; and

about 20 wt % of glass fibers;

wherein a weight ratio of the first poly(aliphatic ester)-polycarbonate copolymer to the second poly(aliphatic ester)-polycarbonate copolymer is at least 1;

1; and

wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm³/10 min;

a flexural modulus measured according to ISO 178 of at least 5000 MPa; and

a notched Izod impact strength measured according to ASTM D256 of at least 190 J/m.

64. A composition comprising:

a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 25,000;

a second poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 30,000 to about 40,000;

a polysiloxane-polycarbonate copolymer; and

about 30 wt % of glass fibers;

wherein a weight ratio of the first poly(aliphatic ester)-polycarbonate copolymer to the second poly(aliphatic ester)-polycarbonate copolymer is at least 1;

1; and

wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm³/10 min;

a flexural modulus measured according to ISO 178 of at least 5500 MPa; and

a notched Izod impact strength measured according to ASTM D256 of at least 90 J/m.

65. The composition of claim 64, wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm³/10 min;

a flexural modulus measured according to ISO 178 of at least 6000 MPa; and

a notched Izod impact strength measured according to ASTM D256 of at least 150 J/m.

66. An article made from the composition of claim 64.

70. An article made from the composition of claim 65.

67. A composition comprising:

about 36 wt % of a first poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 15,000 to about 25,000;

about 24 wt % of a second poly(aliphatic ester)-polycarbonate copolymer having a weight average molecular weight of from about 30,000 to about 40,000;

about 20 wt % of a polysiloxane-polycarbonate copolymer; and

about 20 wt % of glass fibers;

wherein the composition exhibits a melt volume rate measured according to ASTM D1238 of at least 4 cm³/10 min;

a flexural modulus measured according to ISO 178 of at least 500 MPa;

a notched Izod impact strength measured according to ASTM D256 of at least 150 J/m; and

a gloss measured according to ASTM D2457 (at 60°

) of at least 40.